Monday, December 1, 2008

Drywall...with a conscience

A colleague of mine at Philadelphia University recently told me about a new drywall plant in PA that is actually built right next to a coal-fired power plant in order to readily capture the synthetic gypsum byproduct for use in their drywall. I am looking into sourcing all our drywall from this plant.

The facility produces wallboard using recaptured gypsum, uses 100 percent recycled paper for the surfaces of the finished wallboard products, recycles 100 percent of its production waste and feature a closed-loop liquid effluent system, which translates to zero discharge into nearby waterways.It was purposefully located right across the road form the Montour (coal-fired) Power Plant.At the power plant, scrubbers (the environmental controls that remove the sulfur dioxide from the emissions of coal-fired power plants) work by spraying a mixture of crushed limestone and water onto the exhaust gas before it goes out the plant’s chimney. The limestone and water react with the sulfur in the plant’s exhaust to form synthetic gypsum, which is collected and shipped to the USG facility that is across the road from the power plant.

OR...if that doesn't pan out

Green Depot actually stocks drywall that contains 95% recycled coal ash that they get from another Pennsylvania drywall plant (also USG, I believe) that employs the same process as the Washingtonville plant, it's just not right across the street from the power plant.

The price per sheet is virtually the same as any other drywall. We are going to look into both options but seeing that we need have drywall on site in two days...it looks like we might be giving Green Depot a call. It's nice to know they're close by.

2 comments:

It is my understanding that the "scrubbing process" separates the harmful byproducts (carbon dioxide and nitrogen oxide...which go to the stacks and get filtered) from the sulfur portion of the coal exhaust by adding in the dampened limestone element (or other sorbent). The calcium slurry reacts with the sulfur and forms hydrous calcium sulfate (or gypsum). Synthetic gypsum meets all the purity standards that natural gypsum (which you could basically eat if you so desired) meets.

This blog documents the renovation of our personal residence, a 100-yr. old rowhouse in Philadelphia. We learned so much along the way that we wanted to share our experience and research with others.

We'd love to hear from you. Contact us at info[at]solibs.com or visit our company website: solibs.com.

Photos of the house

Project Specs

The original two-story house was 900 SF without a functional kitchen, plumbing that barely worked, and significant roof damage. It was essentially a liveable shell, but it had solid bones and plenty of potential.

We gutted the entire house while salvaging & recycling as much as possible along the way. By adding a third floor and extending the house at the rear, we'll ultimately have 1,850 SF with 3 BR/2.5 BA/Study, as well as a full unfinished basement for storage.

The project is currently registered with the USGBC and is pursuing LEED for Homes Platinum certification.To see Floor Plansand Elevations of the project, see the Wednesday, May 7th blog post.

Well, last week we finally said goodbye to our old plywood roof hatch. Our beautiful new hatch arrived last Monday and it took a total of a...

Bench Dog Design

Bench Dog Design is the creative team behind the design & fabrication of several key features of Montrose Green including the stair treads, bartop, vanity cabinet, wall surfacing, outdoor bench, and roof access ladder. All of these elements were made from locally salvaged wood and fabricated in Bench Dog's own Philadelphia workshop.

Open House Party - 7/11

A big thank you to the nearly 300 people who joined us on 7/11 to tour the house! For those who missed the big event, check out the upcoming Open House schedule above. Click the image above to see a slideshow of photos from the party!